Dry wall slot diffuser extrusion frame with volume and directional control

ABSTRACT

A one piece dry wall extrusion frame comprising: a frame, pre-drilled installation holes in said frame; a lip for plastering; volume control or damper control, linear bars or perforated metal; capture recesses for plaster; and not additional hardware for drop in installation.

PRIOR FILED APPLICATION

The present application claims priority to provisional application No. 63/160,048 filed Mar. 12, 2021.

FIELD OF THE INVENTION

The present invention relates to a one piece dry wall slot diffusion extrusion frame with self-contained volume control, a directional control or both.

BACKGROUND OF THE INVENTION

The prior art requires multiple planar extensions and complexities requiring more costly material/extrusions. With the prior art, one cannot create a radius or curved frame.

SUMMARY OF THE INVENTION

The present invention relates to a one piece dry wall extrusion frame slot diffuser with self-contained adjustable volume control, adjustable directional control or both. It is an object of the present invention for the dry wall extrusion frame to need no additional hardware for drop in installation for walls and ceilings. It is and object of the present invention for the dry wall extrusion frame to comprise pre-drilled or punched installation holes, a lip for plastering, and capture recesses for plaster. It is an object of the present invention for the frame to comprise multiple predrilled or pre-punched holes. It is an object of the present invention for the frame to mount flush to the wall.

The present invention relates to a one piece dry wall extrusion frame slot diffuser with self-contained adjustable volume control and adjustable directional control comprising a flange located below the top surface of the frame, pre-drilled installation holes, a lip for plastering and multiple capture recesses for plaster.

It is an object of the present invention for the slot diffuser frame to fit into a rough opening and to mount flush to a wall or ceiling. It is an object of the slot diffuser to comprise linear bars. It is an object of the present invention for the slot diffuser to not contain linear bars. It is an object of the slot diffuser to require no structural beam, stud, cross member, or structure or support for mounting. This eliminates the need for the installer to locate the position and spacing of a structural element, wall stud or support beam, greatly reducing installation time and labor costs and the skill level of an installer.

It is an object of the present invention for the dry wall extrusion frame to comprise a structure constructed of four extrusions welded, snapped, clipped or press fit together to create a strong, single unit frame. It is an object of the present invention for the frame to comprise a flexible mounting flange.

It is an object of the present invention for the flange to enable an installer with basic skills to position the frame at a wall, floor, ceiling, duct, can, plenum or ventilation inlet or outlet opening.

It is an object of the present invention for the dry wall extrusion frame to not require fixturing, fastening or attachment to a structural building element, wall stud or support beam. This eliminates the need for the installer to locate the position and spacing of a structural element, wall stud, truss, or support beam, greatly reducing installation time and labor costs and the skill level of an installer.

It is an object of the present invention for the frame to comprise numerous pre-punched through holes to which standard securing devices to secure the unit to a wall, or ceiling. It is an object of the present invention for the securing devices to comprise standard wall board or sheet rock screws. It is an object of the present invention for the frame to alternatively be attached with construction adhesive or silicone.

It is an object of the present invention for the flexible mounting flange to contact multiple recesses to capture wallboard compound, mud or plaster.

It is an object of the present invention for the extrusion frame to have pre-drilled mounting holes providing many mounting options to address multiple wall, or ceiling conditions.

It is an object of the present invention for the extrusion frame to be a fully welded construction that provides exceptional strength for mounting in walls, and ceilings.

It is an object of the present invention for the frame to be constructed with clips or connectors.

It is an object of the present invention for the extrusion frame to have pre-drilled holes accurately sized for standard wall board/sheet rock screws so no special hardware or tools are required.

It is an object of the present invention for the frame to be constructed with four extrusion lengths, which can be cut to any length, and welded, clipped or press fit together at the corners to create a strong, one piece unit, structure; in a square, geometric, rectangular or radius shape.

It is an object of the present invention to have unlimited shape possibilities for the frame, including but not limited to radius, square, rectangular, geometric, angular, round, triangular, concave and convex.

It is an object of the present invention for the extrusion frame to allow an installer to cut a very rough hole or opening in a wall or ceiling and slip the extrusion frame into the opening, duct, can, plenum or ventilation inlet or outlet. It is an object of the present invention for thereto be no routing or recessed cut that is necessary. It is an object of the present invention for thereto be no blocking or added wood supports necessary for attachment to a wall or ceiling.

It is an object of the present invention for the extrusion frame to combine the exceptional strength and light weight characteristics of aluminum material—thus enabling safe use in ceiling applications.

It is an object of the present invention for the frame to comprise a projection that is perpendicular to the mounting flange for providing an installer with a natural guide for a wallboard compound, plaster or mud knife to simplify application of plaster, mud or spackle compound.

It is an object of the present invention for the frame to include a projection that goes into an opening providing stability and a mounting point for a damper or Filter.

It is an object of the present invention for the frame to mount flush so that a perforated metal panel or linear bars attached to the frame is also flush to the wall.

It is an object of the present invention for the frame to comprise a flange that is large enough to provide left to right and top to bottom positioning adjustability over a rough opening to an installer, saving time and the need to precision cut the opening.

It is an object of the present invention for the frame to further comprise a mounting strip or recess to attach and/or insert the damper and/or volume control while embodying a mounting flange, frame structure, and the ability to customize fastening points.

It is an object of the present invention for the frame design to include an extruded or attached projection either as part of the extrusion or fastened, should air flow not be a concern.

It is an object of the present invention for the dry wall extrusion frame to comprise a frame, a damper and/or volume control device having linear bars.

It is an object of the present invention for the dry wall extrusion frame to comprise a frame, a damper and/or volume control device having no linear bars.

It is an object of the present invention for the damper and/or volume control device to be removable to accommodate various air flow requirements.

It is an object of the present invention for the damper and/or volume control to be removable for access to the opening duct, plenum, ventilation inlet or outlet, can or vent.

It is an object of the present invention for the frame to accept linear bars.

It is an object of the present invention for the linear bars to be removable.

It is an object of the present invention for the frame to accept a perforated panel.

It is an object of the present invention for the perforated panel to be removable.

It is an object of the present invention for indented slots to capture joint compound or plaster.

It is an object of the present invention for the frame to have a flexible edge to be used for fastening to a wall or ceiling with pre-perforated through holes.

It is an object of the present invention for a common sheet rock or wall board screw to be threaded into the wall material.

It is an object of the present invention for the frame to be installed with a standard sheet rock or wall board screw before plaster or joint compound is applied.

It is an object of the present invention for the dry wall extrusion frame to be installed in a wall with at least two sheet rock or wall board screws.

It is an object of the present invention for the extrusion frame to have pre-punched mounting through holes providing many mounting options to address multiple wall or ceiling conditions.

It is an object of the present invention for the extrusion frame to have multiple, pre-punched mounting holes for fastening in a wide range of wall and ceiling conditions and materials.

It is an object of the present invention for the extrusion frame to have pre-punched holes accurately sized for standard wall board/sheet rock screws so no special hardware or tools are required.

It is an object of the present invention for the extrusion frame to have multiple indented slots along the mounting flange to provide capture points for joint compound or plaster.

It is an object of the present invention for the extrusion frame to be fully welded, clipped or press fit construction that provides exceptional strength for mounting in both walls and ceilings.

It is an object of the present invention for the extrusion frame to comprise a flexible mounting flange that enables the installer to fasten the frame to uneven walls surfaces.

It is an object of the present invention for the inside of the extrusion frame to extend a minimum of ⅝″ deep into the opening so that the extrusion frame is installed in a wall board or plaster ranging from about ¼″ thru about 1.0″ thick.

It is an object of the present invention for the extrusion frame to be mounted, so that the entire frame and its contents are flush to the wall providing a seamless installation—which makes field painting much easier-also makes future cleaning of the frame simpler as can be done with the wipe of a rag.

It is an object of the present invention for the extrusion frame to be mounted in only one way, so that it cannot be installed backward.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a front view of a plaster frame with a controller between two guide strips for controlling both volume and direction of air.

FIG. 2 shows a front view of a plaster frame having a removable adjustable damper and damper directional blade.

FIG. 3 shows a front view of a plaster frame having a removable adjustable damper and damper directional blade and removable volume controllers.

FIG. 4 shows a front view of a plaster frame having a removable adjustable damper and damper directional blade, removable volume controllers and removable linear bars.

FIG. 5 shows a front view of a plaster frame having a removable adjustable damper and damper directional blade, and removable linear bars.

FIG. 6 shows a front view of a plaster frame having removable volume controllers and removable linear bars.

FIG. 7 shows a front view of a plaster frame having removable volume controllers.

FIG. 8 shows a front view of a plaster frame having removable volume controllers and removable linear bars.

FIG. 9 shows a front view of a plaster frame having removable volume controllers.

FIG. 10a shows a front view of an extrusion plaster frame.

FIG. 10b shows a side view of the extrusion plaster frame.

FIG. 10c shows a side view of the extrusion plaster frame.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows the plaster frame 10 having a controller 20 between two guide strips 25 and 30. The controller 20 controls the volume and direction of the air.

FIG. 2 shows frame projection 50 having a knife edge 58, and flexible flange 52 having recesses 56 and pre-punched mounting holes 54. The figure further shows the removable adjustable damper 60 having damper directional blade 62.

FIG. 3 shows frame projection 70 having a knife edge 78, and flexible flange 72 having recesses 76 and pre-punched mounting holes 74. The figure further shows the removable adjustable damper 80 having damper directional blade 82. Within the frame projection 70 is removable volume controllers 84.

FIG. 4 shows frame projection 100 having a knife edge 108, and flexible flange 102 having recesses 106 and pre-punched mounting holes 104. The figure further shows the removable adjustable damper 110 having damper directional blade 112. Within the frame projection 100 is removable volume controllers 114. The frame projection 100 further comprises removable linear bars 116.

FIG. 5 shows frame projection 120 having a knife edge 128, and flexible flange 122 having recesses 126 and pre-punched mounting holes 124. The figure further shows the removable adjustable damper 130 having damper directional blade 132. The frame projection 100 further comprises removable linear bars 134.

FIG. 6 shows frame projection 140 having a knife edge 148, and flexible flange 142 having recesses 146 and pre-punched mounting holes 144. The figure further shows the removable volume controllers 150. The frame projection 100 further comprises removable linear bars 152.

FIG. 7 shows frame projection 160 having a knife edge 168, and flexible flange 162 having recesses 166 and pre-punched mounting holes 164. The figure further shows the removable volume controllers 170.

FIG. 8 shows frame projection 180 having a knife edge 188, and flexible flange 182 having recesses 186 and pre-punched mounting holes 184. The frame projection 100 further comprises removable volume controllers 190 and removable linear bars 192.

FIG. 9 shows frame projection 200 having a knife edge 208, and flexible flange 202 having recesses 206 and pre-punched mounting holes 204. The frame projection 200 further comprises removable volume controllers 210.

FIG. 10a shows dry wall extrusion frame 220 comprised of extrusion pieces 222, 224, 226, and 228. Each extrusion piece has multiple pre-drilled mounting holes 230.

FIG. 10b shows flexible mounting flange 232.

FIG. 10c shows projection into opening 234 and knife guide 236. 

1. A one piece dry wall extrusion frame comprising: a frame; pre-drilled installation holes in said frame; a lip for plastering; a removable volume controller; a removable damper; capture recesses for plaster.
 2. The extrusion frame of claim 1 further comprising: removable linear bars.
 3. The dry wall extrusion frame of claim 1 wherein said frame mounts flush to a wall.
 4. The dry wall extrusion frame of claim 1 wherein said frame is constructed of four extensions welded, clipped or press fit together to create a single piece frame.
 5. The dry wall extrusion frame of claim 1 wherein said frame comprises a flexible mounting flange.
 6. The dry wall extrusion frame of claim 5 wherein said flexible mounting flange enables an installer to position said frame at a wall, ceiling, duct or ventilation opening.
 7. The dry wall extrusion frame of claim 5 wherein said flexible mounting flange contains multiple recesses to capture mud, plaster, or wallboard compound.
 8. The dry wall extrusion frame of claim 5 further comprising a projection that is perpendicular to said mounting flange for providing an installer with a natural guide for a wallboard compound, plaster or mud knife to apply plaster , mud or spackle compound.
 9. The dry wall extrusion frame of claim 1 wherein said frame further comprises a projection that goes into an opening providing stability and a mounting point for a damper or filter.
 10. The dry wall extrusion frame of claim 1 wherein said frame is mounted flush to a wall so that perforated metal or linear bars are attached to said frame that is flush mounted to said wall.
 11. The dry wall extrusion frame of claim 5 wherein said flange is large enough to provide left to right and top to bottom positioning adjustability.
 12. The dry wall extrusion frame of claim 1 wherein said volume control is self-contained and adjustable.
 13. The dry wall extrusion frame of claim 1 wherein said frame has no need for additional hardware for drop installation for walls and ceilings.
 14. The dry wall extrusion frame of claim 1 further comprising: a mounting strip or recess to attach or insert said damper or volume control.
 15. The dry wall extrusion frame of claim 1 further comprising: a perforated panel.
 16. The dry wall extrusion frame of claim 1 wherein said controller is located between guide strips.
 17. The dry wall extrusion frame of claim 1 wherein said damper further comprises directional blades.
 18. A dry wall extrusion frame comprising: a frame; a damper; a volume control device; linear bars or a perforated panel. 